Method and apparatus for measuring wall thickness, ovality of tubular materials

ABSTRACT

The wall thickness and ovality of a tubular are simultaneously determined. The theoretical radius of a pipe is computed from a measurement of its circumference. An ultrasonic device conventionally used to measure the wall thickness of tubulars is adapted to also measure the maximum and minimum diameters and ovality by equipping or utilizing existing ultrasound inspection device with contact surfaces which contact the tubular at a fixed distance apart and at a known distance from the surface of the ultrasonic transducer. The contact surfaces define a chord of known length on the tubular under test. The mean radius of the tubular may be computed from multiple water path measurements around the circumference relative to a known fixture. The maximum and minimum diameter and ovality are calculated from the measured differences in distance from the surface of the tubular to the ultrasonic transducer and the theoretical circle. Wall thickness and ovality may be correlated relative to position by using the same apparatus for both measurements.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/367,031filed Mar. 2, 2006, now U.S. Pat. No. 7,231,314 which claims priority toa provisional patent application by the same inventor, entitled: “Methodand Apparatus for Measuring Wall Thickness, Ovality of TubularMaterials,” Ser. No. 60/657,853, filed on Mar. 2, 2005.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to methods and devices for measuring thedimensions and mechanical properties of pipes, tubes and the like. Moreparticularly, it relates to an ultrasonic device which measures the wallthickness and the maximum and minimum diameter using an ultrasonicprobe, instrumentation and a triangulated fixture. It includessubsequent calculations of the wall thickness eccentricity and theassociated ovality [roundness] of the pipe and tube relative toposition.

2. Description of the Related Art

A perfect circle is the most desirable cross section for tubulars. Itprovides the greatest strength—i.e., resistance to both internal andexternal pressure—of any known shape. Moreover, a perfectly [or nearperfect] circular cross section facilitates the joining of tubulars tofittings, additional sections of tubular material and the like.

Wall thickness and wall integrity are also important parameters oftubular materials. In general, thicker walls and walls that are freefrom defects in the material forming the wall provide greater strengthand hence greater safety. The combination of the wall thickness andassociated ovality data along the length of the tubular is necessarycalculations to determine collapse and burst pressures.

In the past, wall thickness and ovality have been measured separately,using two different measuring devices. Most commonly, wall thickness hasbeen measured using an ultrasonic instrument with a transducer coupledto the tubular under test with a liquid [water] interface. The time forthe ultrasonic waves to reflect from both the external and internalsurfaces of the tubular is converted into distance (wall thickness)using the measured the time and the known velocity of the sound wave inthe material.

Diameter is presently measured using a mechanical device such as amicrometer, an optical device such as a laser or camera or multipleultrasound transducers or an array mounted to a known diameter fixturereference which surrounds the tubular.

An oval may be considered a flattened circle or an ellipse. An ellipseis a closed plane curve generated by a point moving in such a way thatthe sums of its distances from two fixed points (foci) is a constant.The length from one side of an ellipse to the other which passes throughboth foci may be considered its major diameter. A line perpendicular tothe major diameter and passing through the ellipse at its widest partmay be considered its minor diameter. Ovality may be defined as beingthe major diameter minus minor diameter. A perfect circle has an ovalityof zero. Alternatively, pipe ovality may be expressed as a percentage:% Pipe Ovality=100×(Max. Diameter−Min. Diameter)/Mean Diameter

There are many useful applications for applying diameter, ovality, wallthickness and eccentricity determinations to pipe and tubes. Engineersuse the combination of pipe wall thickness and ovality for their burstand collapse calculations The process of bending straight pipe to makeit into a coil distorts its original, circular cross-section into anoval and leaves it with a permanent curvature. Codes prohibit installingpipe that is more than 5% oval. The diameter and ovality (shape) of pipeends can greatly complicate aligning the ends for butt-welding the pipestogether. Drill pipe is subjected to both outside and inside wear due tothe environment. Codes govern the dimensional properties of drill pipe.

SUMMARY OF THE INVENTION

The present invention comprises a method and apparatus for measuringwall thickness and ovality of tubular materials. The invention alsoprovides a method for adapting an ultrasonic device used for measuringthe wall thickness on a pipe or tube, to also measure the maximum andminimum diameter and ovality. The transducer water path is measuredusing a known triangulated fixture for positioning the transducerrelative to the surface of the pipe or tube and the mean radius andcenter is computed. The mean radius, arc height (H) and ½ chord length(C) are related by the derived equation: R=(C²/2H)+H/2. Diameter (andassociated ovality) may be calculated by applying the measured archeight changes to the mean radius and calculating actual pipe radius atdifferent positions around the circumference of the pipe or tube.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a cross sectional view of a tubular in contact with anultrasonic measuring device.

The dimensions of the triangulated fixture (including height) are fixed,thus any change in the measured water path results in a correspondingopposing increase or decrease in the chord height (A). From the abovediagram the following relationship applies:H=R−AR−H=square root (R ² −C ²)And further simplified R=C ²/2H+H/2The preferred fixture contact points subtend an arc angle from 90 to 180degrees.

DETAILED DESCRIPTION

Referring now to FIG. 1, a tubular 2 of diameter D is shown in contactwith measuring device 12 comprised of ultrasonic transducer 6 andcoupler 4 which may be filled with a fluid which may, in someembodiments, be water.

Coupler or shoe 4 may include contact rollers 10 for contacting theexternal surface of pipe 2. The height E (H+W) from the ultrasonictransducer 6 and a chord connecting the contact points of rollers 10 isdetermined by manufacture and may be measured.

In certain embodiments, fixture 12 is not equipped with rollers 10.Nevertheless, the height E from the chord joining the points of contactand the transducer is fixed and may be measured with a high degree ofaccuracy.

It will be appreciated by those skilled in the art that the water pathdistance W between transducer 6 and the external surface of pipe 2 maybe measured electronically by measuring device 12.

The mean radius of pipe 2 is calculated using the average arc heights(H) for one revolution, the fixed (measured) transducer-to-chorddistance E (where E=H+W), and the equation:R=C ²/2H+H/2

The mean radius of the pipe describes the theoretical pipe center andcircumference to which the ovality has been applied. The diameter andcircumference may be calculated from the equations of a circle.Alternately the circumference may be measured and the theoretical pipecenter and radius calculated.

The theoretical circle describes the real pipe circumference andapplicable center for a circle, for an oval shape it is assumed that thechange in (A) relative to the major and minor axis will be negated andthe difference between the measured maximum and minimum arc height abovethat of the theoretical circle center will provide for the approximatemaximum and minimum diameter of the pipe. The ovality can be calculatedusing the difference between the maximum and minimum diameter per piperevolution.

It is known in the industry that the same ultrasonic probe that is usedto measure the water path (W) can also be used to measure the wallthickness at the same location. Eccentricity may be calculated using thevariation in wall thickness per revolution of the pipe.

Since maximum and minimum diameter (ovality) may be determined usingsubstantially the same apparatus as that used to measure wall thicknessand eccentricity they can be correlated relative to position.

While the present invention has been described with respect to a limitednumber of embodiments, those skilled in the art will appreciate numerousmodifications and variations therefrom. It is intended that the appendedclaims cover all such modifications and variations as fall within thetrue spirit and scope of this present invention.

1. A method for correlating wall thickness and ovality of a tubular itemat selected positions along the length of the tubular item comprising:determining the circumference of the tubular item at selected positions;calculating the diameter of a circle having a circumference equal to thedetermined circumference; rotating the tubular item while measuring theobserved maximum and minimum diameters; measuring the wall thickness ofthe tubular item while the tubular item is being rotated; calculatingthe ovality of the tubular item using the difference between the maximumand minimum diameters determined per revolution; correlating calculatedovality and measured wall thickness values; and reporting correlatedovality and wall thickness values.